ASTM E119 - Thermasteel, Inc

ASTM E119

PERFORMANCE TEST REPORT

Report No.: F1663.01-121-24

Test Date: October 7, 2015

Rendered to:

THERMASTEEL CORPORATION

Radford, Virginia

PRODUCT TYPE: Loadbearing Wall Assembly SERIES/MODEL: 5-1/2 inch thick ThermaSteel Wall Panel

This report contains in its entirety: Cover Page: 1 page Report Body: 8 pages Graphical Data: 2 pages Numerical Data: 8 pages Photographs: 6 pages Drawings: 1 page

Test Report No.: F1663.01-121-24 Report Date: 11/17/2016

Test Record Retention End Date: 10/07/2019 Page 1 of 8

1.0 Report Issued To: ThermaSteel Corporation

609 West Rock Road Radford, Virginia 24141 2.0 Test Laboratory: Architectural Testing, Inc., an Intertek company (“Intertek-ATI”) 130 Derry Court York, Pennsylvania 17406-8405 717-764-7700 3.0 Test Method Information:

3.1 Introduction: The purpose of Fire Resistance testing is to measure a building element’s ability to resist the transfer of energy and hot gases through the element and subjecting adjacent rooms, structures, etc. from a single standardized fire scenario. The standard measures this performance by quantifying the temperature rise on the unexposed face of the building element when the exposed side is subjected to the ASTM E119 Time vs. Temperature curve. It addition to exposing the element to the fire test, the standard references procedures for the element to be able to resist the cooling effects of a water hose stream test. After the fire test, the specimen is subjected to the hose stream procedures outlined in ASTM E2226. If the end-use of the element is intended for structural support, it must also maintain its integrity by holding the design load during the standard fire exposure and hose stream procedures. It is important for the user of fire standards and data generated from them to understand the method only exposes the system to one standard exposure. The standard does not address every possible scenario or hazard associated with an actual fire.

4.0 Project Summary: 4.1 Product Type: Loadbearing Wall Assembly 4.2 Series/Model: 5-1/2 inch thick ThermaSteel Wall Panel 4.3 Compliance Statement: Results obtained are tested values and were secured by using the designated test method(s). The specimen(s) were tested and evaluated against the requirements of the standard. A summary of the results is listed in the Test Results section and the complete graphical test data is included in Appendix A of this report. 4.4 Test Date: 10/7/2015 – 10/16/2015 4.5 Ambient Conditions: 71°F and 61% RH on 10/7/2015 4.6 Test Location: Intertek-ATI test facility in York, Pennsylvania 4.7 Test Sample Source: The wall panel sections were selected by Intertek-ATI personnel (Reference Intertek-ATI Sample Report# F1663.02-117-38-R0). The Thermasteel Wall Panels were witnessed during production and tagged prior to shipment on 9/30/2015. Specimens were marked with “MCH”.

130 Derry CourtYork, PA 17406

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www.archtest.com www.intertek.com/building



4.0 Project Summary: (Continued) 4.7 Test Method(s), Practices and/or Classifications: ASTM E119-14, Standard Test Methods for Fire Tests of Building Construction and Materials 4.8 List of Official Observers:

Name Company

Tim Thomas ThermaSteel Corporation Art Parker Jensen-Hughes Matt Freeborn Intertek-ATI Ethan Grove Intertek-ATI Scott Gingrich Intertek-ATI

5.0 Test Specimen Description:

5.1 Interior Wall Cladding: The simulated interior surface of the assembly was clad with three layers of 5/8 inch thick National Gypsum Gold Bond® Fire-Shield® Type-X Gypsum Board (complying with ASTM C1396). Fastener spacing for each layer was 12 inches on center on each wall panel framing member. The first layer of Type-X gypsum board was oriented vertically and fastened to each vertical framing member as well as the top and bottom track with #6 x 1-1/4 inch long self-drilling, bugle head fasteners. The second layer of Type-X gypsum board was oriented horizontally and fastened to each vertical framing member as well as the top and bottom track with #6 x 2 inches long self-drilling, bugle head fasteners. The third layer of Type-X gypsum board was oriented vertically and fastened to each vertical framing member as well as the top and bottom track with #8 x 3 inch long self-drilling, bugle head fasteners. All joints and fastener heads of the third layer of gypsum were Level II finished with USG Sheetrock paper joint tape and spackled with USG Sheetrock Joint Compound. 5.2 Structural Component: 5-1/2 inch thick Thermasteel Wall Panels were assembled prior to installation into the test frame. The designated exterior surface of the assembly was assembled by fastening the 18 gauge galvanized steel flange to the framing member of the panel beside with #12 x 3/4 inch long self-drilling fasteners every 12 inches. 18 gauge nominal 2 inches x 4 inches gusset plates were place at the mid-height (5 feet) of the assembly at each panel joint and fastened to the panels with three #12 x 3/4 inch long self-drilling fasteners into each panel. Once assembled, 18 gauge x 5-1/2 inches wide galvanized steel track was then placed at the top and bottom of the assembly and fastened to each vertical framing member with two #12 x 3/4 inch long self-drilling fasteners per framing member.


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5.0 Test Specimen Description: (Continued) 5.3 Exterior Sheathing: The simulated exterior surface of the assembly was clad with one layer of 5/8 inch thick National Gypsum Gold Bond® eXP® Gypsum Sheathing (complying with ASTM C 1177). Fastener spacing for the sheathing was 12 inches on center on each wall panel framing member. Fasteners used on the sheathing were #6 x 1-1/4 inch long self-drilling, bugle head fasteners.

6.0 Test Details: 6.1 Equipment: Furnace used for testing has an exposure space of 14 ft. wide by 12 ft. tall by 4 ft. deep. The furnace is equipped with six burners capable of producing 1.5 MBtu/hr of energy each. Three burners are positioned on each side wall of the furnace to allow for an even distribution of heat flux across the surface area of the test specimen. The exposed area of the furnace is reduced to 10 ft. by 10 ft. by utilizing a frame consisting of steel and concrete with the exposed surface protected by fiber ceramic blankets. The temperature inside the furnace is controlled by adjusting the blower speed of the air provided to the burners. This temperature is determined by the average of the nine thermocouples symmetrically placed behind the assembly. The neutral-pressure-plane is controlled by two pressure transducers that adjust the opening of the damper.

6.2 Loading Calculation & Procedure: Four RC-258 ENERPAC single acting actuators were spaced evenly below a reinforced steel free floating beam that held the test specimen and framing blocks. Specimen was centered on this beam to allow concentric loading. Sides of the assembly were held in place with lumber and set screws to allow for in-plane loading only, but did not constrain the sides. The hydraulic lines of the actuators were attached to a manifold system and that created pressure by an electric pump. When pumped, the actuators lifted the free floating beam so the test specimen was bearing on the top of the frame. The specimen was loaded to 1,033 psi 15 minutes prior to the start of the test and load was maintained until noted in the observation section of this report.


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6.0 Test Details: (Continued) 6.3 Loading Calculation & Procedure:

𝐹𝑡 = 𝑊 + 𝐷𝐿 ∗ 𝑁

𝐴 = 𝑁𝑎 ∗ 𝐴𝑒𝑓𝑓.

𝑃 =𝐹𝑡

𝐴

Variable Description Value Unit

W Uniform Load of Dead Weight 2,290 lb. DL Design Load* 38,500 lb. N Number of Studs* N/A -- Na Number of Actuators 4 --

Aeff. Effective Area / Actuator 5.15 in.2

A Total Area 20.6 in.2 Ft Total Force 40,790 lb. P Pressure in Hydraulic Line 1,980 PSI

*Design load based on pounds/lineal feet calculation.


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6.0 Test Details: (Continued) 6.4 Test Observations:

10/7/2016 Test #1

Time

(hr:min:sec) Observations

Fire Exposure 00:00 Baseline Deflection Measurement

Left 1/4: 5-1/2 inches from assembly Centerline: 5-1/4 inches from assembly Right 1/4: 5-1/8 inches from assembly

02:00 Ignition of exposed cladding. 19:00 Deflection Measurement


32:00 Deflection Measurement


45:00 Deflection Measurement


1:00:00 Deflection Measurement


1:15:00 Deflection Measurement

Left 1/4: 6 inches from assembly Centerline: 6-3/4 inches from assembly Right 1/4: 5-7/8 inches from assembly

1:18:00 Structural failure determined by inability to withstand actuator pressure and sustain the design load. Fire endurance test continued for nonloadbearing data purposes.

1:30:00* Flames emitting from the exposed gypsum joints. 1:48:00* Third layer of exposed gypsum fallout. 2:00:00* Fire endurance test concluded.

Hose Stream* The hose stream did not penetrate through the unexposed surface during

the test. The wall system was not under load during the hose stream procedure. This is considered a 2-hour fire-rated non-load bearing system only.

*Observations taken under non-load bearing conditions at these elapsed times.


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6.0 Test Details: (Continued) 6.5 Test Results: Testing under Loadbearing Conditions:

Variable Description Test Value

C Correction Factor N/A seconds I Indicated FR Period 120 minutes

A Area under Indicated FR Period for first ¾ of test period N/A

As Area under Standard E119 Time vs. Temp. Curve for first ¾ of test period N/A

L Lag Correction 3240 °F*min FR Period Fire-Resistance Period 78 minutes

Testing under Nonloadbearing Conditions (after witnessed structural failure):

Variable Description Test Value

C Correction Factor 11 seconds I Indicated FR Period 120 minutes

A Area under Indicated FR Period for first ¾ of test period 132444

As Area under Standard E119 Time vs. Temp. Curve for first ¾ of test period 132749

L Lag Correction 3240 °F*min FR Period Fire-Resistance Period 120 minutes

7.0 Test Conclusion:

The load-bearing assembly described in this report and tested by Intertek-ATI achieved a 78 minute fire-resistance rating when tested in accordance with ASTM E119 under loadbearing conditions. Under nonloadbearing conditions, the test assembly described in this report and tested by Intertek-ATI achieved a 120 minute fire-resistance rating when tested in accordance with ASTM E119 under nonloadbearing conditions.


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Intertek-ATI will service this report for the entire test record retention period. The service life of this report will expire on the stated Test Record Retention End Date, at which time such materials as drawings, data sheets, samples of test specimens, copies of this report, and any other pertinent project documentation, shall be discarded without notice. This report does not constitute certification of this product nor an opinion or endorsement by this laboratory. It is the exclusive property of the client so named herein and relates only to the specimen(s) tested. This report may not be reproduced, except in full, without the written approval of Intertek-ATI. For INTERTEK-ATI: __________________________________ ____________________________________ Ethan Grove Karl Houser, P.E. Project Manager – Fire Testing Sr. Fire Protection Engineer EJG:ddr Attachments (pages): This report is complete only when all attachments listed are included.

Appendix A: Graphical Data (2) Appendix B: Numerical Data (8) Appendix C: Photographs (6) Appendix D: Drawings (1)


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Revision Log

Rev. # Date Page(s) Revision(s)

0 11/17/2016 N/A Original Report Issue

This report produced from controlled document template ATI 00662, revised 04/30/15.


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Test Record Retention End Date: 10/07/2019

Appendix A

Graphical Data


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Graph No. 1

Average Furnace Temperature vs. Standard Temperature

0

200

400

600

800

1000

1200

1400

1600

1800

2000

0 20 40 60 80 100 120

Tem

pe

ratu

re (

°F)

Time (minutes)

E119 Curve

Actual TestCurve


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Graph No. 2

Unexposed Surface Temperatures

0

50

100

150

200

250

300

350

400

450

0 20 40 60 80 100 120

Temp.(°F)

Time (minutes)

TC Ave.

TC 1

TC 2

TC 3

TC 4

TC 5

TC 6

TC 7

TC 8

TC 9

Average TC Limit

Single TC Limit

TC 10


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Appendix B

Numerical Data


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Time (min) Ave. Temp Furnace

0 70

1 236

2 355

3 747

4 986

5 1033

6 1077

7 1219

8 1240

9 1268

10 1290

11 1345

12 1336

13 1337

14 1386

15 1397

16 1403

17 1426

18 1432

19 1438

20 1466

21 1468

22 1473

23 1488

24 1495

25 1505

26 1516

27 1523

28 1531

29 1538

30 1545

31 1552

32 1558

33 1562

34 1571

35 1579

36 1586

37 1590

38 1594


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39 1600

40 1606

41 1608

42 1618

43 1619

44 1622

45 1631

46 1632

47 1642

48 1644

49 1645

50 1654

51 1655

52 1663

53 1666

54 1669

55 1676

56 1675

57 1681

58 1685

59 1689

60 1692

61 1693

62 1700

63 1701

64 1705

65 1709

66 1713

67 1716

68 1717

69 1723

70 1725

71 1730

72 1731

73 1735

74 1737

75 1740

76 1742

77 1747

78 1748


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79 1753

80 1755

81 1755

82 1762

83 1763

84 1767

85 1770

86 1773

87 1773

88 1781

89 1782

90 1787

91 1787

92 1791

93 1793

94 1796

95 1799

96 1801

97 1804

98 1805

99 1811

100 1812

101 1815

102 1816

103 1820

104 1820

105 1825

106 1825

107 1830

108 1829

109 1832

110 1832

111 1833

112 1840

113 1836

114 1841

115 1845

116 1839

117 1846

118 1845


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119 1846

120 1848

121 1847

122 1849

123 1852

Table 1

Average Furnace Temperature


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Time (Hr:Min:Sec)

TC Ave.

TC 1 TC 2 TC 3 TC 4 TC 5 TC 6 TC 7 TC 8 TC 9 TC 10

0:00:00 73 73 74 72 72 74 72 72 72 73 73

0:01:00 73 73 74 72 72 74 72 72 72 73 73

0:02:00 73 73 74 72 72 74 72 72 72 73 73

0:03:00 73 73 74 72 72 74 72 72 72 73 73

0:04:00 73 73 74 72 72 74 72 72 72 73 73

0:05:00 73 73 74 72 72 74 72 72 72 73 73

0:06:00 73 73 74 72 72 74 72 72 72 73 73

0:07:00 73 73 74 72 72 74 72 72 72 73 73

0:08:00 73 73 74 72 72 74 72 72 72 73 73

0:09:00 73 73 74 72 72 74 72 72 72 73 73

0:10:00 73 73 74 72 72 74 72 72 72 73 73

0:11:00 73 73 74 72 72 74 72 72 72 73 73

0:12:00 73 73 74 72 72 74 72 72 72 73 73

0:13:00 73 73 74 72 72 74 72 72 72 73 73

0:14:00 73 73 74 72 72 74 72 72 72 73 73

0:15:00 73 73 74 72 72 74 72 72 72 73 73

0:16:00 73 73 74 72 72 74 72 72 72 73 73

0:17:00 73 73 74 72 72 74 72 72 72 73 73

0:18:00 73 73 74 72 72 74 72 72 72 73 73

0:19:00 73 74 74 72 72 74 73 72 72 73 73

0:20:00 73 74 74 72 72 74 73 72 72 73 73

0:21:00 73 74 74 72 72 74 73 72 72 73 73

0:22:00 73 74 74 72 72 74 73 72 72 73 73

0:23:00 73 74 74 72 72 74 73 72 72 73 73

0:24:00 73 74 75 72 72 74 73 73 72 73 73

0:25:00 73 74 75 72 72 74 73 73 72 73 73

0:26:00 73 74 75 72 72 74 73 73 72 73 73

0:27:00 73 74 75 72 72 74 73 73 72 73 73

0:28:00 73 74 75 72 72 74 73 73 72 73 73

0:29:00 73 74 75 72 72 74 73 73 72 74 73

0:30:00 73 74 75 72 72 74 73 73 72 74 73

0:31:00 73 74 75 72 72 74 73 73 72 74 73

0:32:00 73 74 75 72 72 74 73 73 72 74 73

0:33:00 73 74 75 72 72 74 73 73 72 74 73

0:34:00 73 74 75 73 72 74 73 73 72 74 74

0:35:00 73 74 75 73 72 74 73 73 72 74 74

0:36:00 73 74 75 73 72 74 73 73 72 74 74

0:37:00 73 74 75 73 72 74 73 73 72 74 74

0:38:00 73 74 75 73 72 74 73 73 72 74 74


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Time (Hr:Min:Sec)

TC Ave.


0:39:00 74 74 75 73 73 75 73 73 72 74 74

0:40:00 74 75 75 73 73 75 73 73 72 74 74

0:41:00 74 75 75 73 73 75 73 73 72 74 74

0:42:00 74 75 76 73 73 75 73 73 72 74 74

0:43:00 74 75 76 73 73 75 74 73 72 74 74

0:44:00 74 75 76 73 73 75 74 73 72 74 74

0:45:00 74 75 76 73 73 75 74 73 72 75 74

0:46:00 74 75 76 73 73 75 74 73 72 75 74

0:47:00 74 75 76 73 73 75 74 73 72 75 74

0:48:00 74 75 76 74 73 75 74 73 72 75 74

0:49:00 74 75 76 74 73 75 74 74 73 75 75

0:50:00 74 75 76 74 73 75 74 74 73 75 75

0:51:00 74 75 76 74 73 76 74 74 73 75 75

0:52:00 75 75 76 74 73 76 74 74 73 75 75

0:53:00 75 76 77 74 73 76 74 74 73 75 75

0:54:00 75 76 77 74 74 76 74 74 73 75 75

0:55:00 75 76 77 74 74 76 75 74 73 76 75

0:56:00 75 76 77 74 74 76 75 74 73 76 75

0:57:00 75 76 77 75 74 76 75 74 73 76 75

0:58:00 75 76 77 75 74 76 75 74 73 76 76

0:59:00 75 76 77 75 74 77 75 75 74 76 76

1:00:00 75 76 77 75 74 77 75 75 74 76 76

1:01:00 76 76 78 75 74 77 75 75 74 76 76

1:02:00 76 77 78 75 74 77 75 75 74 76 76

1:03:00 76 77 78 75 75 77 76 75 74 76 76

1:04:00 76 77 78 75 75 77 76 75 74 77 76

1:05:00 76 77 78 76 75 78 76 75 74 77 77

1:06:00 76 77 78 76 75 78 76 75 74 77 77

1:07:00 76 77 79 76 75 78 76 75 74 77 77

1:08:00 76 77 79 76 75 78 76 75 75 77 77

1:09:00 77 77 79 76 75 78 76 76 75 77 78

1:10:00 77 78 79 77 75 78 77 76 75 77 78

1:11:00 77 78 79 77 75 79 77 76 75 78 78

1:12:00 77 78 80 77 76 79 77 76 75 78 79

1:13:00 77 78 80 77 76 79 77 76 75 78 79

1:14:00 77 78 80 77 76 79 77 76 75 78 80

1:15:00 78 78 80 78 76 79 78 76 76 78 80

1:16:00 78 78 80 78 76 80 78 76 76 78 80

1:17:00 78 79 81 78 76 80 78 77 76 79 80


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Time (Hr:Min:Sec)

TC Ave.


1:18:00 78 79 81 78 76 80 78 77 76 79 81

1:19:00 78 79 81 78 77 80 78 77 76 79 81

1:20:00 78 79 81 78 77 80 78 77 76 79 81

1:21:00 79 79 82 79 77 80 79 77 77 79 82

1:22:00 79 79 82 79 77 81 79 77 77 79 82

1:23:00 79 80 82 79 77 81 79 77 77 80 82

1:24:00 79 80 82 79 77 81 79 78 77 80 83

1:25:00 79 80 83 79 78 81 79 78 77 80 83

1:26:00 80 80 83 80 78 82 80 78 78 80 83

1:27:00 80 80 83 80 78 82 80 78 78 80 83

1:28:00 80 80 83 80 78 82 80 78 78 80 84

1:29:00 80 81 84 80 78 82 80 79 78 81 84

1:30:00 80 81 84 81 79 83 80 79 78 81 84

1:31:00 81 81 84 81 79 83 80 79 78 81 85

1:32:00 81 81 84 81 79 83 81 79 79 81 85

1:33:00 81 81 84 81 79 83 81 79 79 81 85

1:34:00 81 82 84 81 79 83 81 79 79 82 86

1:35:00 81 82 85 82 79 83 81 80 79 82 86

1:36:00 82 82 85 82 80 84 81 80 79 82 86

1:37:00 82 82 85 82 80 84 82 80 80 82 86

1:38:00 82 82 85 82 80 84 82 80 80 82 87

1:39:00 82 83 86 82 80 84 82 80 80 82 87

1:40:00 82 83 86 83 80 84 82 80 80 83 87

1:41:00 83 83 86 83 81 85 82 81 80 83 87

1:42:00 83 83 86 83 81 85 83 81 81 83 88

1:43:00 83 83 86 83 81 85 83 81 81 83 88

1:44:00 83 83 87 83 81 85 83 81 81 83 88

1:45:00 83 84 87 83 81 85 83 81 81 84 88

1:46:00 83 84 87 84 81 85 83 81 81 84 88

1:47:00 84 84 87 84 81 85 83 82 81 84 89

1:48:00 84 84 87 84 82 85 83 82 81 84 89

1:49:00 84 84 87 84 82 86 84 82 82 84 89

1:50:00 84 84 87 84 82 86 84 82 82 84 89

1:51:00 84 85 88 84 82 86 84 82 82 84 89

1:52:00 84 85 88 85 82 86 84 82 82 85 89

1:53:00 84 85 88 85 82 86 84 82 82 85 89

1:54:00 85 85 88 85 82 86 84 83 82 85 90

1:55:00 85 85 88 85 83 87 84 83 83 85 90

1:56:00 85 85 88 85 83 87 85 83 83 85 90


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Time (Hr:Min:Sec)

TC Ave.


1:57:00 85 85 88 85 83 87 85 83 83 85 90

1:58:00 85 86 89 85 83 87 85 83 84 85 90

1:59:00 86 86 89 86 84 87 86 83 85 85 90

2:00:00 88 86 91 86 87 89 95 86 91 86 91

Max Temp. 85 86 89 86 84 87 86 83 85 85

PASS/FAIL PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS

Table No. 2


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Appendix C

Photographs


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Photo No. 1

Sampling Markings on Wall Panels

Photo No. 2

Wall Panel Assembly


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Photo No. 3

Installation of First Layer of Type-X Gypsum

Photo No. 4

Installation of Second Layer of Type-X Gypsum


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Photo No. 5

Installation of Third Layer of Type-X Gypsum

Photo No. 6

Installation of Exterior Type-X Gypsum


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Photo No. 7

Complete Assembly (Pre-test)

Photo No. 8

Evidence of Structural Failure


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Photo No. 9

End of Fire Resistance Test

Photo No. 10

Exposed Surface after Fire Resistance Test


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Photo No. 11

Post Hose-stream Test


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Appendix D

Drawings


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Documents

ASTM E119 - Thermasteel, Inc